Method of manufacturing an environment-friendly tile

ABSTRACT

A new type environment-friendly tile and method of manufacturing the same, firstly, provide a multi bottom-fiber layer containing a environment-friendly water-borne resin; next, place a top wear-resistant layer made of thermoplastic polyurethane (TPU) on a top surface of said multi bottom-fiber layer, and perform hot pressing and lamination on them, so that said multi bottom-fiber layer is laminated and connected to said top wear-resistant layer utilizing said environment-friendly water-borne resin. The new type environment-friendly tile thus produced is not only light weight, and highly wear resistant, but its manufacturing method is also creative and innovative, and since it is made of environment-friendly material such as fiber and thermoplastic polyurethane (TPU), hereby realizing human health and environment protection requirements.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of co-pending application Ser. No.13/191,826, filed on Jul. 27, 2011, for which priority is claimed under35 U.S.C. §120, the entire contents of which are hereby incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a technology of manufacturing tiles,and in particular to a new type environment-friendly tile and method ofmanufacturing the same.

2. Brief Description of the Prior Art

Due to the needs of indoor decoration and the floor pavement, theplacement of tiles on the floor is quite common. In general, the tile isdesigned to be the plastic tile made of ceramic or polyvinyl chloride(PVC), thus its price can be varied depending on material it is made andits size.

In the prior art, the ordinary plastic tile contains halogen, orvolatile materials, that is not environment friendly. Moreover, in thepast, the so called environment friendly plastic tile was made of Ureaformaldehyde resin, modified melamine, or phenolic resin, etc containingvarious degrees of toxicity, and that does not conform to therequirements of human health. By way of example, in Taiwan Patent No1280998 is disclosed a method of producing a plastic tiles havingenhanced wear resistant surface, and the plastic tile is as shown inFIG. 1. The steps of manufacturing this kind of plastic tiles are asfollows: firstly, prepare at least a polyvinyl chloride (PVC) bottomplate 10 and a surface glue layer 12, and glue them together, wherein,the surface of the surface glue layer 12 is pre-coated with a wearresistant glue, such that the side of the surface glue layer 12 notcontaining the wear resistant glue is glued to the PVC bottom plate 10;then upon the gluing the PVC bottom plate 10 and the surface glue layer12 together, it is hot pressed and rolled into shape; and subsequently,cut it into the individual plastic tiles. From the descriptionsmentioned above it can be known that, though the results of better wearresistance can be obtained, however, the PVC bottom plate still containshalogen, and that still poses hazard to the environment.

Therefore, presently, the design and performance of the tile of theprior art is not quite satisfactory, and it has much room forimprovements.

SUMMARY OF THE INVENTION

In view of the problems and shortcomings of the prior art, the presentinvention provides a new type environment-friendly tile and method ofmanufacturing the same. It is quite a departure from the ordinaryplastic tile manufacturing technology, and it is made of environmentfriendly material, such as water-bone resin, fiber layer, andthermoplastic polyurethane (TPU), that conform to the human healthrequirement. In addition, the high wear resistance and high slipperyresistance of the thermoplastic polyurethane (TPU) can effectivelyincrease the service life of the tile.

In order to achieve the above objective, the present invention providesa new type environment friendly tile, including: a multi bottom-fiberlayer containing a first environment-friendly water-borne resin; and atop wear-resistant layer made of thermoplastic polyurethane (TPU), andis disposed on top of the bottom-fiber layer, such that the two types oflayers are connected and laminated into shape.

Also, the present invention provides a new type environment-friendlytile manufacturing method, comprising the following steps: prepare amulti bottom-fiber layer containing first environment-friendlywater-borne resin; then put a top wear-resistant layer made ofthermoplastic polyurethane (TPU) on the top surface of the multibottom-fiber layer; and subsequently, laminate and hot press these twotypes of layers to connect to each other and form into shape.

Further scope of the applicability of the present invention will becomeapparent from the detailed descriptions given hereinafter. However, itshould be understood that the detailed descriptions and specificexamples, while indicating preferred embodiments of the presentinvention, are given by way of illustration only, since various changesand modifications within the spirit and scope of the present inventionwill become apparent to those skilled in the art from this detaileddescriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

The related drawings in connection with the detailed descriptions of thepresent invention to be made later are described briefly as follows, inwhich:

FIG. 1 is a cross section view of a tile according to the prior art;

FIG. 2 is a cross section view of a tile according to a first embodimentof the present invention;

FIGS. 3( a) to 3(b) are the cross section views of a tile correspondingto the steps of manufacturing the tile according to the first embodimentof the present invention;

FIGS. 4( a) to 4(b) are the cross section views of a multi bottom-fiberlayer corresponding to steps of manufacturing the multi bottom-fiberlayer according to the first embodiment of the present invention;

FIG. 5 is a cross section view of a tile according to a secondembodiment of the present invention;

FIGS. 6( a) to 6(b) are the cross section views of a tile correspondingto steps of manufacturing the tile according to the second embodiment ofthe present invention; and

FIGS. 7( a) to 7(b) are schematic diagrams showing the steps ofmanufacturing a decoration fiber layer according to the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The purpose, construction, features, functions and advantages of thepresent invention can be appreciated and understood more thoroughlythrough the following detailed description with reference to theattached drawings.

The present invention provides a new type environment-friendly tile.Refer to FIG. 2 for a cross section view of a new typeenvironment-friendly tile according to a first embodiment of the presentinvention. As shown in FIG. 2, the environment friendly tile comprises:a multi bottom-fiber layer 16 containing a first environment-friendlywater-borne resin 14, wherein, the multi bottom-fiber layer 16 includesa multi fiber layer 17 containing a first environment-friendlywater-borne resin 14, and this multi fiber layer 17 is made of at leasta paper layer, at least a wood layer, or at least a cork layer, or acomposite layer of the paper layer, the wood layer, and the cork layer.For the first environment-friendly water-borne resin 14, thethermoplastic polyurethane (TPU) glue is taken as an example forexplanation, and that includes: 25-50% polyurethane (PU) emulsion, 5-15%sodium stearate, 20-40% water, 1-10% glycerin, 0-10% polyvinyl alcohol(PVA). On the top surface of the multi bottom-fiber layers 16 isprovided with a top wear-resistant layer 18 made of thermoplasticpolyurethane (TPU), such that the multi bottom-fiber layer 16 utilizesthe first environment-friendly water-borne resin 14 to connect to thetop wear-resistant layer 18. Since the thermoplastic polyurethane (TPU)glue does not belong to the environment non-friendly resin of the priorart, besides, the way of using thermoplastic polyurethane (TPU) and theenvironment friendly material of multi-bottom fiber layers 16 is adeparture from the conventional plastic tile manufacturing technology,thus it conforms to the requirements of human health and environmentprotection. In addition, the thermoplastic polyurethane (TPU) of topwear-resistant layer 18 is highly slippery-proof, and it wear resistancecan be raised 5 to 10 times that of the ordinary polyvinyl chloride(PVC) material, hereby prolonging service life of the tile. On thebottom surface of the multi bottom-fiber layer 16 is provided with abottom wear-resistant layer 20 made of thermoplastic polyurethane orPolyethylene (PE) to protect the multi bottom-fiber layer 16, such thatthe multi bottom-fiber layer 16 utilizes the first environment-friendlywater-borne resin 14 to connect to the bottom wear-resistant layer 20.

In laying tiles on the ground, in case that the ground has a smoothsurface plane already, then the bottom wear-resistant layer 20 can beomitted in achieving the same effect mentioned above.

Then, the method of manufacturing tiles according to the firstembodiment of the present invention is described. Refer to FIGS. 3( a)and 3(b) for the cross section views of a tile corresponding to steps ofmanufacturing the tile according to the first embodiment of the presentinvention. Firstly, as shown in FIG. 3( a), provide a multi bottom-fiberlayer 16 containing the first environment-friendly water-borne resin 14.Next, as shown in FIG. 3( b), place the bottom wear-resistant layer 20,the multi bottom-fiber layer 16 containing first environment-friendlywater-borne resin 14, the top wear-resistant layer 18 from bottom totop, then perform hot pressing and lamination, so that the bottomwear-resistant layer 20, top wear-resistant layer 18, and the multibottom-fiber layer 16 containing the first environment-friendlywater-borne resin 14 are laminated and connected to each other incompleting the manufacturing processes.

In addition, in step of FIG. 3( b), the bottom wear-resistant layer 20can be omitted, so that only the top wear-resistant layer 18 is placedon the top surface of the multi bottom-fiber layer 16, and then performhot pressing and lamination, so that the top wear-resistant layer 18 islaminated and connected with the multi bottom-fiber layer 16 containingthe first environment-friendly water-borne resin 14.

In the following, the method of manufacturing a multi bottom-fiber layer16 is described, refer to FIGS. 4( a) to 4(h) for the cross sectionviews of a multi bottom-fiber layer corresponding to steps ofmanufacturing the multi bottom-fiber layer according to the firstembodiment of the present invention. Firstly, as shown in FIG. 4( a),immerse a multi fiber layer 17 into first environment-friendlywater-borne resin 14 to absorb it. Next, as shown in FIG. 4( b), bakethe multi fiber layer 17 to obtain a multi bottom-fiber layer 16, toproceed with subsequent processes of manufacturing.

Subsequently, the second embodiment of the present invention isdescribed, refer to FIG. 5 for a cross section view of a tile accordingto a second embodiment of the present invention. As shown in FIG. 5, thedifference between the second embodiment and the first embodiment isthat, an additional decoration fiber layer 24 containing the secondenvironment-friendly water-borne resin 22 is added, that is disposedbetween the multi bottom-fiber layer 16 and top wear-resistant layer 18,so that the top wear-resistant layer 18, the decoration fiber layer 24containing the second environment-friendly water-borne resin 22, and themulti bottom-fiber layer 16 are connected to each other. Wherein, thesurface of the decoration fiber layer 24 further has a design pattern,and the decoration fiber layer 24 further includes an original fiberdecoration layer 26 containing the second environment-friendlywater-borne resin 22, such that the original fiber decoration layer 26is a paper layer, a wood layer, or a cork layer. The compositions of thesecond environment-friendly water-borne resin 22 are the same as thoseof the first environment-friendly water-borne resin 14, and herein, thewater-bone thermoplastic polyurethane (TPU) glue is taken as an examplefor explanation, and that includes: 25-50% polyurethane (PIT) emulsion,5-15% sodium stearate, 20-40% water, 1-10% glycerin, 0-10% polyvinylalcohol (PVA).

Similarly, in the second embodiment, the bottom wear-resistant layer 20can also be omitted in achieving the same effect of environmentprotection, while keeping its high wear resistance.

Subsequently, the method of manufacturing the new type of environmentfriendly tile of the second embodiment is described. Refer to FIGS. 6(a) and 6(b) for

cross section views of a tile corresponding to steps of manufacturingthe tile according to the second embodiment of the present invention.Firstly, as shown in FIG. 6( a), provide a multi bottom-fiber layer 16containing the first environment-friendly water-borne resin 14; next, asshown in FIG. (b), dispose from bottom to top the following layers: thebottom wear-resistant layer 20, the multi bottom-fiber layer 16containing the first environment-friendly water-borne resin 14, thedecoration fiber layer 24 containing the second environment-friendlywater-borne resin 22, and the top wear-resistant layer 18, and thenperform hot press and connection, so that the top wear-resistant layer18, the multi bottom-fiber layer 16 containing the firstenvironment-friendly water-borne resin 14, the decoration fiber layer 24containing the second environment-friendly water-borne resin 22, thebottom wear-resistant layer 20 are connected to each other, incompleting the manufacturing of a tile of the present invention.

In addition, in the steps as shown in FIG. 6( b), the bottom wearresistant layer 20 can be omitted. Therefore, dispose from bottom to toponly the following layers: the multi bottom-fiber layer 16 containingthe first environment-friendly water-borne resin 14, the decorationfiber layer 24 containing the second environment-friendly water-borneresin 22, and top wear-resistant layer 18, and then perform hot pressingand connection, so that the top wear-resistant layer 18, the multibottom-fiber layer 16 containing the first environment-friendlywater-borne resin 14, and the decoration fiber layer 24 containing thesecond environment-friendly water-borne resin 22, are connected to eachother to complete the manufacturing of a tile of the present invention.

Since the method of manufacturing a multi bottom-fiber layers 16 hasbeen described in the first embodiment, as shown in FIGS. 4( a) and4(b), so it will not be repeated here for brevity.

Finally, refer to FIGS. 7( a) and 7(b) for schematic diagrams showingthe steps of manufacturing a decoration fiber layer 24 according to thepresent invention. Firstly, as shown in FIG. 7( a), immerse the originalfiber decoration layer 26 into the second environment-friendlywater-borne resin 22 to absorb it. Next, as shown in FIG. 7 (b), bakethe original fiber decoration layer 26 to obtain the decoration fiberlayer 24, for proceeding with the subsequent processes of manufacturinga tile.

Summing up the above, the present invention utilizesenvironment-friendly materials to fulfill the environment protectionrequirement, it further utilizes the characteristic of thermoplasticpolyurethane (TPU) to fulfill the high wear resistance requirement of atile.

The above detailed description of the preferred embodiment is intendedto describe more clearly the characteristics and spirit of the presentinvention. However, the preferred embodiments disclosed above are notintended to be any restrictions to the scope of the present invention.Conversely, its purpose is to include the various changes and equivalentarrangements which are within the scope of the appended claims.

What is claimed is:
 1. A tile manufacturing method, comprising thefollowing steps: providing a multi-fiber layer, having a top surface anda bottom surface, wherein said multi-fiber layer is made from aplurality of fibers and a first water-borne resin; wherein said firstwater-borne resin is a thermoplastic polyurethane (PTU) glue comprising25-50wt % polyurethane (PU) emulsion, 5-15wt % sodium stearate, 20-40wt% water, 1-10wt % glycerin and 0-10wt % polyvinyl alcohol (PVA); andplacing a wear-resistant layer made of thermoplastic polyurethane (TPU)on said top surface of said multi-fiber layer, and performing hot pressand lamination, so that said wear-resistant layer and said multi-fiberlayer are laminated and connected to each other.
 2. The tilemanufacturing method as claimed in claim 1, wherein the step ofmanufacturing said multi-fiber layer further includes steps of:immersing said plurality of fibers into said first water-borne resin toabsorb said first water-borne resin; and baking said plurality of fibersto obtain said multi-fiber layer.
 3. The tile manufacturing method asclaimed in claim 2, wherein said multi-fiber layer further includes: atleast a paper layer, a wood layer, or a cork layer, or a composite layerof said paper layer, said wood layer, and said cork layer.
 4. The tilemanufacturing method as claimed in claim 1, wherein said step of hotpressing and laminating said wear-resistant layer and said multi-fiberlayer, so as to connect said wear-resistant layer and said multi-fiberlayer further includes steps of: placing from bottom to top saidmulti-fiber layer, a decoration fiber layer containing a secondwater-borne resin, and said wear-resistant layer, performing hotpressing and laminating, so that said wear-resistant layer, saiddecoration fiber layer, and said multi-fiber layer are laminated andconnected to each other.
 5. The tile manufacturing method as claimed inclaim 4, wherein said second water-borne resin is the same as saidthermoplastic polyurethane (TPU) glue.
 6. The tile manufacturing methodas claimed in claim 5, wherein the step of manufacturing said decorationfiber layer includes the steps of: immersing an original fiberdecoration layer into said second water-borne resin to absorb saidsecond water-borne resin; and baking said original fiber decorationlayer to obtain said decoration fiber layer.
 7. The tile manufacturingmethod as claimed in claim 6, wherein said original fiber decorationlayer is a paper layer, a wood layer, or a cork layer.
 8. The tilemanufacturing method as claimed in claim 1, wherein said step of hotpressing and laminating said wear-resistant layer and said multi-fiberlayer, so that said wear-resistant layer and said multi-fiber layercontaining said first water-borne resin are laminated and connected toeach other includes the steps of placing from bottom to top awear-resistant layer on said bottom surface of said multi-fiber layer,and said wear-resistant layer on said top surface of said multi-fiberlayer and then performing hot pressing and laminating, so that saidwear-resistant layer on said top surface of said multi-fiber layer, saidwear-resistant layer on said bottom surface of said multi-fiber layerand said multi-fiber layer are connected to each other.
 9. The tilemanufacturing method as claimed in claim 8, wherein said wear-resistantlayer on bottom surface of said multi-fiber layer is made of saidthermoplastic polyurethane (TPU) or polyethylene (PE).